Rapidly Deployable Floor Power System

ABSTRACT

A rapidly deployable floor power system includes a base unit for supplying low voltage DC power to one or more foldable power tracks. Each foldable power track has a set of rigid track sections with exposed track power contacts on a top surface. The rigid track sections are electrically and mechanically interconnected by flexible track connectors that enable the power track to be folded when the power track is to be moved or stored, and unfolded for rapid deployment in an area to be supplied with power. The rigid track sections lie approximately flush with the floor to minimize tripping potential. Magnetic connectors engage the track to obtain power from the track, and are used to electrically interconnect adjacent tracks. A power distribution unit supplies power via low voltage ports such as USB ports and/or via one or more power whips equipped with barrel jack tips.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of PCT/US2018/020378,having an international filing date of Mar. 1, 2018, which claimspriority to U.S. Provisional Patent Application No. 62/523,560, filedJun. 22, 2017, entitled Portable Floor Power System, the content of eachof which is hereby incorporated herein by reference. This application isrelated to U.S. patent application Ser. No. 15/789,356, now U.S. Pat.No. 10,283,952, which also claims priority to U.S. Provisional PatentApplication No. 62/523,560.

BACKGROUND

This disclosure relates to a power distribution systems and, moreparticularly, to a rapidly deployable floor power system.

SUMMARY

All examples and features mentioned below can be combined in anytechnically possible way.

In one aspect, a rapidly deployable floor power system includes a baseunit for supplying low voltage DC power to one or more foldable powertracks. Each foldable power track has a set of rigid track sections withexposed track power contacts on a top surface. The rigid track sectionsare electrically and mechanically interconnected by flexible trackconnectors that enable the power track to be folded when the power trackis to be moved or stored, and unfolded for rapid deployment in an areato be supplied with power. The rigid track sections lie approximatelyflush with the floor to minimize tripping potential. Magnetic connectorsengage the track to obtain power from the track, and are used toelectrically interconnect adjacent tracks. A power distribution unitsupplies power via low voltage ports such as USB ports and/or via one ormore power whips equipped with barrel jack tips.

In one aspect, a rapidly deployable floor power system includes a baseunit for receiving mains power and outputting a DC voltage on a DC poweroutput. The system also includes a foldable power track in electricalcommunication with the base unit to receive the DC voltage, the foldablepower track having a plurality of rigid track sections interconnected byflexible track connectors. The system also includes a power distributionsystem having a first magnetic electrical connector on a first end of apower distribution cable to magnetically connect to the foldable powertrack to receive the DC voltage, the power distribution system furtherhaving a power distribution unit on a second end of the powerdistribution cable, the power distribution unit receiving the DC voltagevia the power distribution cable and converting the DC voltage to asecond DC voltage.

In some implementations, the base unit has a protection circuit toprevent an overcurrent and/or overvoltage condition on the DC poweroutput.

In certain implementations each rigid track section of the foldablepower track has a first profile including a flat top surface and bevelededges, the DC power output has a DC power output profile that matchesthe first profile, and the magnetic electrical connector has a secondprofile to mate with the first profile.

In some implementations, each rigid track section of the foldable powertrack has a first profile including a lower surface, a flat top surface,and beveled edges that taper from the flat top surface to the lowersurface.

In certain implementations, channels are provided, within the flat topsurface of the track sections, to receive exposed track power contactsat the flat top surface.

In some implementations magnetic attractors are provided, below the flattop surface of the track sections, to engage magnets within the magneticconnector.

In certain implementations the base unit has a power conditioningcircuit to prevent the DC voltage from being output on the DC poweroutput if the magnetic connector is not in electrical communication withthe foldable power track.

In some implementations the base unit supplies DC power at approximately36V DC.

In certain implementations each of the rigid track sections has aplurality of exposed track power contacts on a top surface.

In some implementations each of the plurality of exposed track powercontacts extends substantially a length of the top surface.

In certain implementations the exposed track power contacts of a firstof the rigid track sections are electrically connected through theflexible track connectors to exposed track power contacts of a second ofthe rigid track sections.

In some implementations the first rigid track section is connected bythe flexible track connector to the second rigid track section.

In certain implementations the flexible track connector contains wiresdisposed within the flexible track connector to electrically connect theexposed track power contacts of the first and second rigid tracksections.

In some implementations each of the rigid track sections has threeexposed track power contacts.

In certain implementations a first of the three exposed track powercontacts is electrically connected to a positive output terminal of theDC power output, and a second of the three exposed track power contactsis electrically connected to a ground output terminal of the DC poweroutput.

In some implementations a third of the three exposed track powercontacts is electrically connected to a ground output terminal of the DCpower output.

In certain implementations the base unit has a first communication unit,the power distribution unit has a second communication unit, and whereinat least one of the three exposed track power contacts is used to passcommunication signals between the first communication unit and thesecond communication unit.

In some implementations the system further includes a track power cable,the track power cable being electrically connected on a first trackpower cable end to the foldable power track and being electricallyconnected on a second track power cable end to a second magneticconnector, the second magnetic connector having the same shape as thefirst magnetic connector.

In certain implementations the track power cable is fixed on the firsttrack power cable end to the foldable power track.

In some implementations the track power cable is connected to a thirdmagnetic connector on the first track power cable end.

In certain implementations the system further includes at least a secondfoldable power track, having a second track power in electricalcommunication with the first foldable power track.

In some implementations the magnetic electrical connector has threeconnectors that are not in a straight line.

In certain implementations the magnetic electrical connector has atleast three connectors formed in a straight line.

In some implementations the magnetic electrical connector has sixconnectors, a first set of three of the six connectors being in a firststraight line and a second set of three of the six connectors being in asecond straight line, the first straight line being parallel to thesecond straight line.

In certain implementations the DC power output has exposed powercontacts to mate with power contacts of the magnetic electricalconnector.

In some implementations the DC power output has magnetic attractorsspaced to engage magnets of the magnetic electrical connector.

In certain implementations the magnetic electrical connector includes aplurality of magnets a body having a lower exterior surface and a topshell defining an internal cavity, a printed circuit board disposedwithin the internal cavity, a plurality of contacts connected to theprinted circuit board to extend through apertures in the lower surface,and a plurality of springs disposed within the cavity between a topinterior surface of the cavity and the printed circuit board to bias theprinted circuit board to bias the printed circuit board toward the lowersurface.

In some implementations, when the magnetic electrical connector engagesthe foldable power track, the magnets of the magnetic electricalconnector engage magnetic attractors of the foldable power track to pullthe lower surface of the magnetic electrical connector into matingrelationship with a profile of the foldable power track.

In certain implementations, when the magnetic electrical connectorengages the foldable power track, the plurality of contacts are pushedup into the body of the magnetic electrical connector against a biasingforce of the springs.

According to another aspect, a method of rapidly deploying a floor powersystem within a room is provided. The method includes the steps ofunfolding a foldable power track onto a floor of the room, the foldablepower track including a plurality of rigid track sections with exposedDC power contacts on a top surface and a plurality of flexible trackconnectors electrically and mechanically interconnecting the rigid tracksections, electrically connecting a base unit to mains power, the baseunit containing an AC to DC converter to convert AC power received frommains power to output the low voltage DC power on a DC power output, andelectrically connecting the base unit to the foldable power track usinga magnetic connector to interconnect a power cord to the base unit.

In some implementations, the method further includes the steps ofunfolding at least a second foldable power track onto the floor, andusing a magnetic electrical connector to electrically connect the secondfoldable power track to the first foldable power track.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a functional block diagram of a rapidly deployable floor powersystem according to an embodiment.

FIGS. 2A-2C show an example foldable power track deployed flat (FIG.2A), in a state of starting to be folded (FIG. 2B), and fully folded(FIG. 2C).

FIGS. 3-5 show example rapidly deployable floor power systems havingmultiple foldable power tracks electrically interconnected to one ormore base units.

FIG. 6 is a functional block diagram of a power cable having a magneticelectrical connector at each end, each magnetic connector being designedto magnetically engage the base unit and/or one or more rigid tracksections according to an implementation.

FIG. 7 is a functional block diagram of an example base unit accordingto an implementation.

FIG. 8 is a top plan view of two sections of an example foldable powertrack according to an implementation.

FIG. 9 is a cross-sectional view of rigid track section taken along lineA-A of FIG. 8 according to an implementation.

FIG. 10 is a cross-sectional view of a flexible connector taken alongline B-B of FIG. 8 according to an implementation.

FIG. 11 is a perspective view of an example foldable power track for usewith the example floor power system of FIG. 1.

FIG. 12 is a perspective view of a power input end of the examplefoldable power track of FIG. 11.

FIG. 13 is a perspective view of a termination end of the examplefoldable power track of FIG. 11.

FIG. 14 is a perspective view, in partial relief, of two sections of theexample foldable power track of FIG. 11.

FIG. 15 is a cross-sectional view of one of the rigid track sections ofthe example foldable power track of FIG. 11 showing power contacts andmagnetic attractors.

FIG. 16 is a cross-sectional view of the rigid track section of FIG. 15with the power contacts and magnetic attractors removed.

FIG. 17 is a top plan view of one rigid track section of the examplefoldable power track of FIG. 11.

FIG. 18 is a top plan view of an example flexible track connector usedto connect adjacent rigid track sections of the example foldable powertrack of FIG. 11.

FIG. 19 is a perspective view of the example flexible track connector ofFIG. 18.

FIG. 20 is a top plan view of embedded electrical components of theexample flexible track connector of FIG. 18.

FIG. 21 is a cross-sectional view of a magnetic electrical connector inclose proximity to example rigid track section.

FIG. 22 is a cross-sectional view of the magnetic electrical connectorof FIG. 21 in electrical communication with the example rigid tracksection.

FIG. 23 is a cross-sectional view of the magnetic electrical connectorof FIG. 21 in electrical communication with an example base unit.

FIG. 24 is a perspective view of an example magnetic electricalconnector according to an implementation.

FIG. 25 is a bottom view of the example magnetic electrical connector ofFIG. 24.

FIG. 26 is a front view of the example magnetic electrical connector ofFIG. 24, the rear view being a mirror image of the front.

FIG. 27 is a perspective view of an interior of the magnetic electricalconnector of FIG. 24 with the top cover removed.

FIG. 28 is a front view of the example magnetic electrical connector ofFIG. 24 with the top cover and bottom covers removed.

FIGS. 29-31 are functional block diagrams of example power cables havinga magnetic electrical connector at one end and a power distribution uniton the other end according to an implementation.

FIG. 32 is a functional block diagram of an example power distributionunit according to an implementation.

FIG. 33 is an exploded perspective view of an external shell of anexample power distribution unit according to an implementation.

FIG. 34 is a front perspective view of a base unit according to animplementation.

FIG. 35 is a front view of the base unit of FIG. 34.

FIG. 36 is a rear view of the base unit of FIG. 34.

FIG. 37 is a right side view of the base unit of FIG. 34. The left sideview of the base unit is a mirror image of the right side view.

FIG. 38 is a top plan view of the base unit of FIG. 34.

FIG. 39 is a bottom plan view of the base unit of FIG. 34.

FIG. 40 is a top perspective view of a magnetic connector according toan implementation.

FIG. 41 is a bottom perspective view of the magnetic connector of FIG.40.

FIG. 42 is a front view of the magnetic connector of FIG. 40. The rearview of the base unit is a mirror image of the front view.

FIG. 43 is a right side view of the magnetic connector of FIG. 40. Theleft side view of the base unit is a mirror image of the right sideview.

FIG. 44 is a top plan view of the magnetic connector of FIG. 40.

FIG. 45 is a bottom plan view of the magnetic connector of FIG. 40.

FIG. 46 is a top perspective view of a power distribution unit accordingto an implementation.

FIG. 47 is a bottom perspective view of the power distribution unit ofFIG. 46.

FIG. 48 is a front view of the power distribution unit of FIG. 46.

FIG. 49 is a rear view of the power distribution unit of FIG. 46.

FIG. 50 is a right side view of the power distribution unit of FIG. 46.The left side view of the power distribution unit is a mirror image ofthe right side view.

FIG. 51 is a top plan view of the power distribution unit of FIG. 46.

FIG. 52 is a bottom plan view of the power distribution unit of FIG. 46.

DETAILED DESCRIPTION

Electronic devices require access to power to operate. While manydevices have batteries, having an available source of power to rechargethe batteries is often desirable. Unfortunately, available power sourcesare often inconveniently located, particularly in public spaces. Forexample, people attending a conference may be seated in a conferenceroom away from any wall where power might normally be available.Similarly, students may be seated in a classroom away from any availablepower source. Since extension cords are tripping hazards, runningextension cords into the interior area of a room is often an impracticalsolution to providing power toward the middle areas of the room. Whileit may be possible to permanently install electrical outlets within thespace, doing so takes time and often takes considerable cost/effort.Likewise installing temporary power often involves taping or otherwisesecuring loose wires to the floor, which can be unsightly and timeconsuming. Accordingly, it would be desirable to provide a rapidlydeployable floor power system to enable power to be more readilyavailable to be accessible at a larger number of locations. It alsowould be desirable to provide a rapidly deployable floor power systemthat is easily configurable to create new power layout topologies asspace is reconfigured.

FIG. 1 is a functional block diagram of an example rapidly deployablefloor power system 10 according to an implementation. As shown in FIG.1, in one embodiment a rapidly deployable floor power system 10 includesa base unit 12 and one or more lengths of foldable power track 14. Thebase unit 12 and foldable power track 14 are connected by a track powercable 16 having a magnetic connector 18 on one end. The track 14 iselectrically and mechanically connected to the track power cable 16 at atrack input terminal 17. The magnetic connector 18 is designed toelectrically and magnetically connect to the base unit 12.

The rapidly deployable floor power system also includes one or morepower distribution systems 20, each of which includes a powerdistribution cable 22 connected to a power distribution unit 24 on oneend and to a magnetic connector 18 on the other end. In FIG. 1, thepower distribution unit 24 is shown sitting on top of a desk 25. In someembodiments the magnetic connector 18 attached to the end of the trackpower cable 16 is the same as the magnetic connector 18 attached to theend of the power distribution cable 22.

In some embodiments, mains electricity, e.g. 120V/230V AC power, issupplied to base unit from a standard power outlet via power cord 26.Base unit 12 converts AC power received on power cord 26 into DC power,and outputs the DC power to the foldable power track 14 via track powercable 16. In some implementations the track power cable is on the orderof two feet in length, although other lengths may be used depending onthe implementation. In some implementations, base unit 12 outputs DCpower at 36 volts and 8 amps, for a total available power of 288 Wattson foldable power track 14. In other implementations, other DC/currentlevels may be used. The DC current levels in some implementations may beone or more DC levels in a range between 20 V and 50 V. In someimplementations the DC voltage is approximately 36V. In otherimplementations the DC voltages is approximately 48V.

In some implementations, base unit 12 includes a shut-down circuit, forexample as described in U.S. Pat. No. 7,932,638, to prevent a personfrom receiving an electrical shock if they contact both positive andneutral contacts of foldable power track 14, and to cease output ofelectrical power to the track in the event a conductive object comesinto contact with both positive and neutral contacts.

In some implementations, foldable power track 14 is formed from rigidtrack sections 28 interconnected by flexible track connectors 30. Theuse of rigid track sections 28 and interspersed flexible trackconnectors 30 enables the foldable power track to lay flat as shown inFIG. 2A, and to be folded into a compact form for storage, as shown inFIGS. 2B, and 2C. By folding the foldable power track 14 into theposition shown in FIG. 2C, the foldable power track 14 can be folded fortransportation and/or storage. The rigid track sections may be made outof polycarbonate or other suitably dense/solid plastic material toenable the foldable power track 14 to be walked on while disposed on thefloor. A bottom surface of the rigid track sections may be coated with anon-slip rubber or other elastomer to minimize lateral movement of thetrack during normal use.

Although the rapidly deployable floor power system 10 of FIG. 1 showsthe base unit 12 connected to a single foldable power track 14,optionally the base unit 12 can be directly connected to more than onefoldable power track 14. Likewise, as shown in FIG. 1, multiple foldablepower tracks 14 can be electrically connected to each other in series.As noted above, in some implementations the magnetic connector 18 on theend of track power cable 16 is designed to connect to both the base unit12 and to the foldable power track 14. Accordingly, the magneticconnector 18 of a second foldable power track 14 can electricallyconnect to another near-by foldable power track 14. Accordingly, asingle power unit 12 can supply power to multiple daisy-chained foldablepower tracks 14 to enable the single power unit to provide power over anextended area serviced by multiple interconnected foldable power tracks14.

In some implementations a power distribution system 20 can connect via amagnetic connector 18 directly to the base unit 12, to enable the powerdistribution unit 22 to obtain power directly from the base unit 12without the interposition of a foldable power track 14. This furtherenhances the flexibility of the manner in which the rapidly deployablefloor power system can be used to provide power within a room.

FIGS. 3-5 show example rapidly deployable floor power systems havingmultiple foldable power tracks 14 electrically interconnected to asingle base unit. As shown in FIGS. 3-5, the rapidly deployable floorpower system is easily configurable to create new power layouttopologies as space is reconfigured.

FIG. 3 shows an implementation similar to FIG. 1, in which each sectionof foldable power track 14 has a track input terminal 17 connected tothe track which forms one end of the track power cable 16. A magneticconnector 18 on the opposite end of the track power cable 16 allows thetrack power cable 16 to connect to another foldable power track 14 atany location along the length of the other foldable power track 14.

FIGS. 4 and 5 show another implementation in which a dual ended magneticpower cable 32 is used to interconnect the base unit 12 with foldablepower track 14, and to connect between foldable power track sections 14.A functional block diagram of an example dual ended magnetic power cable32 is shown in FIG. 6. As shown in FIG. 6, the dual ended magnetic powercable 32 in this implementation has a magnetic connector 18 on each endof a cable 118. In some implementations the two magnetic connectors 18are identical, and each can mate with either the foldable power track 14or the base unit 12.

FIG. 3 shows a rapidly deployable floor power system having threesections of foldable power track 14 connected together in series.Specifically, in FIG. 3 base unit 12 connects to foldable power track14C. Foldable power track 14B connects to foldable power track 14C, andfoldable power track 14A connects to foldable power track 14B.

FIG. 4 shows a rapidly deployable floor power system having foursections of foldable power track 14 connected together in a branchednetwork. Specifically, in FIG. 3 base unit 12 connects to foldable powertrack 14B. Foldable power track 14A connects in series to foldable powertrack 14B. Foldable power track 14C, like foldable power track 14A, alsoconnects to foldable power track 14B. Foldable power track 14D connectsin series to foldable power track 14C. In this manner the foldable powertracks 14 are able to branch out in different directions from theinitial foldable power track 14 that connects to the base unit 12.

FIG. 5 shows a rapidly deployable floor power system 10 deployed in aroom 34. As shown in FIG. 5, the rapidly deployable floor power system10 includes multiple base units 12, each of which is connected to a setof foldable power tracks 14. As shown in FIG. 5, the foldable powertracks 14 can be placed on the floor in any desired spatial orientationrelative to each other. There is no need for the foldable track sections14 to be placed to be parallel to each other as shown in FIGS. 1, 3, and4, but rather those figures were drawn with parallel track sections forease of illustration. It will be recognized that the foldable powertracks 14 of a given rapidly deployable floor power system 10 may beoriented in any desired direction to provide power within a room 34 orother physical space. Thus, the rapidly deployable floor power system iseasily configurable to create new power layout topologies as space isreconfigured. In some implementations sufficient power may be providedto a room using a single base unit. In other implementations multiplebase units 12 may be used, for example, in a situation where a largernumber of devices are to be provided with power within the room 34.

FIG. 6 is a functional block diagram of a dual ended magnetic powercable 32 having identical magnetic electrical connectors 18 at each end,each magnetic connector being designed to magnetically engage a baseunit 12 and/or one or more foldable power track 14 according to animplementation.

FIG. 7 is a functional block diagram of one example implementation of abase unit 12. Multiple other implementations are possible and likewisethe functional components shown in FIG. 7 may be rearranged depending onthe functionality of the base unit and the particular implementation.Not all functions shown in FIG. 7 are necessary in every implementation.Likewise, a given implementation of a base unit may provide additionalfeatures. The functions described in connection with FIG. 7 may likewisebe consolidated and multiple functions may be implemented using commoncomponents such as by a microprocessor or other processing environment.

In the implementation shown in FIG. 7 the base unit 12 includes an ACpower input 36. The AC power input 36 is connected to an optional GroundFault Interrupt (GFI) and/or fuse 38 to protect the base unit from anovercurrent or over voltage condition on the input AC power supply.Optionally, one or more AC power outlets 40 may be provided at thesurface of the base unit 12 to enable the base unit 12 to also functionas a power strip.

The base unit 12 receives AC power, such as mains electricity, and anAC-DC transformer 42 converts the received power into DC for output tothe foldable power track. In some implementations, the AC-DC transformer42 outputs 36 V DC power at 20 amps.

Power output from AC-DC transformer 42 flows through switch 46 to DCpower output 48. The exterior shape of the DC power output 48 can have aprofile similar to the track profile to be described in greater detailbelow. By forming the DC power output 48 to have the same exteriorprofile as the track, the same magnetic connector 18 can be used toconnect to both the DC power output 48 of the base unit 12 and to thefoldable power track 14. In some embodiments, the DC power output 48includes three power contacts 50 spaced the same distance apart as trackpower contacts 62 on the rigid track sections 28 (described below).

The DC power output 48 also includes magnetic attractors 52 to enablethe magnetic connector 18 to be magnetically attached to the base unit12 in the area of the DC power output 48. Particularly where theexterior shell of the base unit is formed from a plastic or non-ferrousmaterial, including magnetic attractors 52 allows the magnetic connector18 to be mated to the base unit 12 and also serves to align the magneticconnector 18 with the DC power outlet 48 to ensure accurate matingbetween the power contacts 50 of the DC power outlet 48 and contacts ofthe magnetic connector 18. Optionally a lip may at least partiallysurround the DC power outlet 48 on the exterior shell of the base unitto further aid in aligning the magnetic connector 18 with the DC poweroutlet 48.

A protection circuit 54 is provided to detect an over-current conditionon the DC power output. An over-current condition may occur where ashort occurs across the exposed track power contacts 62 of the foldablepower tracks 14. For example, a person may touch two of the exposedtrack power contacts 62 of opposite polarity, or a paperclip or otherconductive object may come into contact with exposed track powercontacts 62 of opposite polarity. In some implementations, theprotection circuit 54 includes a shut-down circuit, for example asdescribed in U.S. Pat. No. 7,932,638, to prevent a person from receivingan electrical shock if the person contacts both positive and neutralcontacts of foldable power track 14, and to prevent the transmission ofpower to the foldable power track 14 in the event a conductive objectcomes into contact with both positive and neutral contacts. In someimplementations the protection circuit senses the output power on DCpower output 48 and activates switch 46 to turn off power on DC poweroutput 48 until the condition has been remedied. Although theimplementation shows the switch 46 interposed between the AC-DCtransformer and the DC power output, the switch 46 may be elsewhere inthe circuit, such as between the AC power input 36 and the AC-DCtransformer.

A power conditioner 56 may optionally be provided in the base unit. Thepower conditioner, in one implementation, is formed to turn off power onthe DC power output 48 until a power consumer has connected to thefoldable power track 14. There is no reason to supply output power tothe foldable power track 14 if no device is connected to the foldablepower track to draw power from the floor power system. When a magneticelectrical connector 18 is connected to the foldable power track 14, thepower conditioner 56 causes the switch to initiate transmission of powerto the foldable power track 14. In some implementations the powerconditioner 56 is implemented as a hot swap circuit.

In some implementations, the base unit 12 further includes a load sensor58 to detect the amount of current being drawn from the DC power output48. The load may be detected, as indicated, from the DC power output 48,from the output of the AC-DC transformer 42, from the protection circuit54, or in another manner. The detected load is used to control operationof one or more LEDs 60. For example, in some implementations when ACpower input 36 is connected to a power source, a first LED 60 isactivated indicating that the base unit 12 is receiving power. When theamount of power drawn by devices connected to the flexible power track14 starts to approach the power limit of the base unit 12, a second LED60 is illuminated. Other LEDs may likewise be provided to indicate otherpower conditions.

In some implementations, the base unit 12 includes a controller 44 ormicroprocessor to implement some of the functions of the protectioncircuit 54, power conditioner 56, and/or load sensor 58.

FIG. 8 is a top plan view of two sections of an example foldable powertrack 14 according to an implementation. FIG. 9 is a cross-sectionalview of a rigid track section 28 of the foldable power track 14 takenalong line A-A of FIG. 8 according to an implementation. FIG. 10 is across-sectional view of a flexible track connector 30 of the foldablepower track 14 taken along line B-B of FIG. 8 according to animplementation.

As shown in FIGS. 8-10, the foldable power track 14 includes rigid tracksections 28 interconnected by flexible track connectors 30. The rigidtrack sections 28 have exposed power contacts 62 extending along theirupper surface. Magnetic attractors 64 are formed along outside edges ofthe rigid track sections 28 to enable the magnetic connectors 18 tomagnetically engage the rigid track sections 28 of the foldable powertrack 14. Wires 66 disposed within flexible track connectors 30electrically connect the power contacts 62 of one rigid track section 28to the next rigid track section 28, so that power supplied to one rigidtrack section 28 will be conducted the length of the foldable powertrack 14.

FIG. 11 is a perspective view of an example foldable power track 14according to an implementation. As shown in FIG. 11, the foldable powertrack 14 includes a plurality of rigid track sections 28 interconnectedby flexible track connectors 30. The foldable power track 14 shown inFIG. 11 includes eight rigid track sections 28 interconnected by sevenflexible track connectors 24. In other implementations different numbersof rigid track sections 28 and flexible track connectors 30 may be used.Rigid track sections 28 may be of any desired length. In someimplementations the rigid track sections 28 are between 1-4 feet inlength, although other length rigid track sections 28 may likewise beused depending on the implementation. Rigid track sections 28 of a givenfoldable power track 14 may be all of the same length or, alternatively,may have different lengths. The width of the rigid track sections 28 maybe on the order of 3-6 inches wide, or another width depending on theimplementation.

FIG. 12 is a perspective view of a track input terminal 17 of theexample foldable power track of FIG. 11, and FIG. 13 is a perspectiveview of a termination end 68 of the example foldable power track of FIG.11. As shown in FIG. 12, power enters the track input terminal 17 of thefoldable power track 14 via track power cable 16 and is distributed bytrack input terminal 17 to track power contacts 62A, 62B, 62C.

In some implementations, track power contacts 62A, 62B, 62C are formedas aluminum plates that are accessible along their length from a topsurface 70 of the rigid track section 28. Although aluminum is apreferred material for formation of track power contacts 62, othermaterials such as copper may likewise be used. The particular materialselected for track power contacts 62 will depend on the amount of powerto be delivered by the track power contacts 62 as well as the dimensionsof the track power contacts 62.

In some implementations the track power contacts 62A, 62B, 62C extendsubstantially the entire length of each of the rigid track sections 28.In some implementations the track power contacts 62A, 62B, 62C extendthe entire length of each of the rigid track sections 28. As shown inFIG. 12, each track section has a set of track power contacts 62A, 62B,62C which extend along its top surface 70. Having track power contacts62A, 62B, 62C exposed on the top surface 70 of the rigid track section28 along the length of the rigid track section 28 enables multipleelectrical connections to be made to the track power contacts 62A, 62B,62C along the length of the foldable power track 14, and allowsvariability as to where the electrical connection should be made.

In some embodiments, track power contacts 62A and 62C are used asground, and track power contact 62B is positive. As noted above, in someembodiments the voltage difference between positive and ground may be 36volts DC. In other embodiments, other voltage levels may be used. Inother embodiments, track power contacts 62A and 62C may be positive andtrack power contact 62B may be ground. In still another embodiment, afirst of the track power contacts may be used as ground, a second of thetrack power contacts may be used to carry positive DC power at a firstvoltage level, and a third of the track power contacts may be used tocarry positive DC power at a second voltage level. In addition tosupplying DC power on the track power contacts 62A, 62B, 62C, in someimplementations communication signals are also transmitted on one ormore of the track power contacts. In some implementations transmissionof data signals on one or more of the track power contacts 62 may beimplemented via signals overlayed on the DC voltage on any one or moreof the track power contacts 62. In other implementations one of thetrack power contacts 62 is used as a dedicated data channel.

In some implementations communication between the base unit and othercomponents within the rapidly deployable floor power system isimplemented using passive communication, such as by causing the baseunit to sense power conditions on the track. For example, in someimplementations the base unit senses power conditions on power contacts50 as power distribution systems are connected within the rapidlydeployable floor power system to verify that the power distributionsystem is an approved load. In some implementations RC time constantsare used to implement this communication. For example, in someimplementations, the base unit uses a known time constant and a forwardvoltage drop across a diode to verify an “approved” load.

Although the implementation shown in FIG. 12 shows the track powercontacts 62A, 62B, 62C as having the same surface area, in someimplementations the track power contacts 62 may have different widths.

As shown in FIG. 13, the termination end 68 in some implementations isrounded and beveled to minimizing tripping hazard presented by thefoldable power track 14. In some implementations, the foldable powertrack 14 likewise has beveled edges 44 extending from floor level to thetop surface 42 to minimize tripping hazard presented by the foldablepower track 14, and to enable wheeled items to more easily roll over thefoldable power track.

FIG. 14 is a perspective view, in partial relief, of two rigid tracksections 28 of the example foldable power track of FIG. 11. As shown inFIG. 14, in some implementations each rigid track section 28 has threetrack power contacts 62 and two magnetic attractors 64. Magneticattractors 64, in some implementations, are rods or bars offerromagnetic materials extending the length of the rigid track section28. In some implementations a ferromagnetic bar, such as an iron plateor steel plate is disposed in a channel adjacent each beveled edge 72.

FIGS. 15-16 show an example cross-sectional views of an example rigidtrack section 28. FIG. 15 shows the rigid track section 28 including thetrack power contacts 62A, 62B, 62C, as well as magnetic attractors 64.FIG. 16 shows the rigid track section 28 alone, with the power trackpower contacts 62A, 62B, 62C, and magnetic attractors 64 removed. Asshown in FIGS. 15-16, in some implementations the rigid track section 28is formed from extruded plastic having a plurality of channels 74 forreceiving the track power contacts 62A, 62B, 62C, and magneticattractors 64. Channels 74 also serve to receive tongues 92 of the rigidtail pieces of the flexible track connector 30 (described below).

The height of the rigid track sections 28, in some implementations, ison the order of ¼ inch. Minimizing the height profile of the rigid tracksections 28 when deployed on the floor is advantageous to preventtripping. The height, in some implementations, is dependent on theability to mechanically interconnect the flexible track connectors 30with adjacent rigid track section 28. Optionally an elastomer may beapplied to a lower surface of the rigid track sections 28 to prevent therigid track sections 28 from slipping when deployed.

In some embodiments the magnetic attractors 64 are retained within abody of the rigid track section 28 by magnetic attractor grooves 76. Forexample, ferromagnetic bars may be slid into the magnetic attractorgrooves 76 of channels 74B and 74E prior to connecting the rigid tracksection 28 to flexile track connectors 28.

In some embodiments, track power contacts 62A, 62B, 62C are retained bypower contact grooves 78 formed along edges of power contact channels80A, 80B, and 80C formed in the top surface 70 of the rigid tracksection 28. For example, aluminum bars may be slid into the powercontact grooves 78 of the power contact channels 80A, 80B, 80C prior toconnecting the rigid track section 28 to flexible track connectors 30.

As shown in FIG. 15, in some implementations the track power contacts62A, 62B, 62C are formed to sit slightly below the top surface 70 of therigid track section 28. By recessing the track power contacts 62slightly below the top surface 70 of the rigid track section 28, apaperclip or other metallic/conductive item that happens to fall ontothe top surface 70 is less likely to form an electrical connectionbetween adjacent track power contacts 62 and, hence, the track is lesslikely to short out.

FIG. 17 shows an example rigid track section 28 with two attachedflexible track connectors 30. During manufacturing, the body of therigid track section 28 is extruded, power contacts 62 are inserted asdiscussed above, and magnetic attractors are inserted as discussedabove. Flexible track connectors 30 are then attached to the rigid tracksection 28, for example by inserting tongues 92 into channels 74.

FIGS. 18 and 19 show an example flexible track connector 30 in greaterdetail. As shown in FIG. 18, in some implementations the flexible trackconnector 30 has rigid tail pieces 82 interconnected by a flexibleribbon 84. Electrical connectors 86 extend between the rigid tail pieces82 through the flexible ribbon 84. In some implementations eachelectrical connector 86 has a brass tip 88 at each end interconnected bya jacketed wire 90. The jacketed wire 90 may be, for example, a 12 or 14gauge copper wire that is soldered on each end to brass tips 88.

Each rigid tail piece 82 has tongues 92A-92F that are shaped to fit intocorresponding openings 74A-74F of the extruded the track body (see FIG.15). Insertion of tongues 92A-92F into openings 74A-74F maintainsalignment of the top surface 70 of the track with the top surface of therigid tail piece 82.

Each rigid tail piece 82 also has retaining clasps 94 havingwedge-shaped tips that engage with corresponding apertures (not shown)formed in the track body when the tongues 92A-92F are inserted intocorresponding openings 74A-75F of the track body. Wedges thusmechanically connect the rigid tail pieces 82 to the rigid tracksections 28.

During assembly, the wedge-shaped retaining clasps 94 will slide underregions 96 (see FIG. 15) causing legs 98 of the retaining clasps 94 tobend slightly. When the wedge-shaped tips encounter the apertures in theregion 76, the legs 98 will snap back into place causing thewedge-shaped tips to engage the apertures to mechanically connect therigid tail piece 82 to the track body. Although a mechanical connectionhas been described, other manners of connecting the rigid tail piece 82to the track body may be utilized as well, such as through the use ofadhesives or ultrasonic welding.

FIG. 20 shows the flexible ribbon 84 and electrical connectors 86 ingreater detail. As shown in FIG. 20, the flexible ribbon 84 is formed asa pliable sheet substantially the width of the top surface 70 of therigid track section 28, and is molded around jacketed wires 90 ofelectrical connectors 86. Preferably a material such as Thermo-PlasticUrethane (TPU) is used, which may be injection molded around jacketedwires 90.

In some implementations, the rigid tail pieces 82 are first injectionmolded using a relatively rigid plastic material such as polycarbonate.Two identical tail pieces are then brought to a second molding process,in which the TPU is injection molded around the wires 90 and stubsformed on the rigid tail pieces 82. By injection molding the TPU of theflexible ribbon 84 to engage the stubs of the rigid tail pieces 82, itis possible to securely join the rigid tail pieces 82 with the flexibleribbon 84.

FIG. 21 is a cross-sectional view of an example magnetic connector 18configured to electrically connect with the track power contacts 62 ofan example rigid track section 28, when the magnetic connector 18 is inclose proximity to the example rigid track section 28 and before makingcontact with the rigid track section 28. FIG. 22 is a cross-sectionalview of the magnetic connector 18 once the magnetic connector 18 hasmated with the example rigid track section 28.

As shown in FIG. 21, in one implementation the magnetic connector 18 hasthree contacts 100A, 100B, 100C spaced to respectively engage powercontacts 62A, 62B, 62C of the rigid track section 28. Contacts 100 maybe formed of copper, aluminum, or another conductive material, and insome implementations have planar bottom surfaces to engage powercontacts 62A, 62B, 62C of rigid track section 28.

The three contacts 100A, 100B, 100C, in one implementation, are rigidlyattached to a printed circuit board 102 that is biased downward bysprings 104 to extend out of a lower surface of the magnetic connector18. Printed circuit board 102 can move relative to base 106 such that,when contacts 100 engage track power contacts 62, the printed circuitboard is moved upward into the magnetic connector 18 against the forceof the springs 104. Magnets 108 in magnetic connector 18 are attractedto magnetic attractors 64 to pull the body of the magnetic connector 18into engagement with rigid track section 28. Contacts 100 initiallyextend outward from a bottom surface of the magnetic connector. Theforce of the magnets pulls the bottom surface of the magnetic connectoragainst the top surface 70 of the rigid track section 28, which alsocauses contacts 62 to force contacts 100 upward into the magneticconnector 18 against the force of the springs 104. In this mannersprings 104 are able to urge contacts 100 into firm engagement withtrack power contacts 62. Magnets 108 also ensure alignment of thecontacts 100 of magnetic connector 18 and with contacts 62 of the rigidtrack section 28.

FIG. 23 is a cross-sectional view of the example magnetic connector 18configured to electrically connect with a DC power output interface 48of a base unit 12. As shown in FIG. 23, in some embodiments the baseunit 12 has a DC power output interface 48 having external surfaceshaped with the same profile as the rigid track section 28, and haspower output contacts 50A, 50B, 50C spaced to have the same relativespacing as the spacing of the track power contacts 62A, 62B, 62C.Magnetic attractors 52 are likewise provided in the base unit 12 toenable the magnetic connector 18 to magnetically engage with the baseunit 12 in the same manner as the magnetic connector 18 engages with therigid track sections 28 of the flexible power track 14.

FIGS. 24-28 show an implementation of a magnetic electrical connector18. As shown in FIG. 24, in some implementations the magnetic electricalconnector 18 has a strain relief member 95 formed where the magneticelectrical connector 18 is connected to the power distribution cable 22.In some implementations the strain relief member 95 may be made oftranslucent plastic to light up when the magnetic electrical connector18 is properly connected to the foldable power track 14 and receivingpower from the base unit 12. Optionally printed circuit board 102 mayinclude one or more LEDs (not shown) that output light when power ispresent.

FIG. 25 shows a lower surface 112 of the magnetic electrical connector18. As shown in FIG. 25, in some implementations the lower surface 112includes three apertures 101 through which contacts 100 extend. In otherimplementations, for example as shown in FIG. 41, the magneticelectrical connector 18 has six contacts 100 instead of the illustratedthree contacts 100 shown in FIG. 25. Use of a larger number of contacts100 may enable greater power transfer between contacts 100 of themagnetic electrical connector 18 and the track power contacts 62. Insome implementations, magnetic electrical connectors 18 connected totrack power cables 16 have six contacts 100, so that the magneticelectrical connectors 18 used to receive power from the base unit 12 andto transfer power between daisy-chained foldable power tracks 14 areprovided with a higher surface area for transfer the relatively higherpower flowing through these connections. In some implementations themagnetic electrical connectors 18 connected to power distribution cable22 have three contacts 100, as shown in FIG. 25, due to the reducedamount of power required to be handled in the connections associatedwith providing power from the foldable power track 14 to the powerdistribution units 24.

As shown in FIG. 26, in some embodiments the lower surface 112 of themagnetic electrical connector 18 has a profile to match the profile ofthe upper surface 40 of the rigid track sections 28 of the foldablepower track 14.

FIGS. 27 and 28 show one arrangement of the printed circuit board 102,contacts 100, and springs 104 of an example magnetic electricalconnector 18. As shown in FIGS. 27 and 28, in one implementation thecontacts 100 are screwed onto printed circuit board 102. Springs 104 arepositioned directly opposite the contacts 100 and optionally arelikewise connected to the printed circuit board using the same screwthat is used to hold the contacts 100 on the printed circuit board.Springs 104 bias the printed circuit board 102 away from a top interiorsurface 114 of a cavity 116 formed within the magnetic electricalconnector 18 (see FIG. 21). The body of the magnetic electricalconnector 18, in some embodiments, is formed of plastic and, as such,does not conduct electricity. Accordingly, the fact that the springs 104are in electrical communication with contacts 100 does not result in ashort circuit between the various contacts within the magneticelectrical connector. Wires (not shown) of cable 12 or cable 22 areconnected to the printed circuit board.

FIGS. 29-31 are functional block diagrams of example power distributionunits 24 connected by cable 22 with a magnetic electrical connector 18to receive power from the foldable power track 14. FIGS. 29-30 show animplementation in which the power distribution unit 24 includes aplurality of female low voltage DC output ports 122. Example DC outputports 122 may be USB ports. FIG. 31 shows an implementation in which thepower distribution unit 24 includes a plurality of power whips 124, eachof which is equipped with a DC connector 126, such as a cylindricalplug, for supplying power, e.g., to a laptop computer.

FIG. 32 is a functional block diagram of an example power distributionunit 24 according to an implementation. As shown in FIG. 32, the powerdistribution unit 24 has a DC power input 128. A first DC-DC transformer130 converts DC power received at DC power input 128 to a first voltagelevel for presentation at a first set of DC ports 132. In someimplementations the first voltage level is 5 V DC and the first set ofDC ports 132 are USB ports. Although FIG. 32 shows two first DC ports132, a larger or smaller number of ports may be used depending on theimplementation.

Optionally a second DC-DC transformer 134 converts DC power received atDC power input 128 to a second voltage level for presentation at asecond set of DC ports 136. In some implementations the second voltagelevel is 20 V DC and the second set of DC ports 136 are DC connectors126 such as cylindrical DC connectors on ends of power whips 124.Although FIG. 32 shows two second DC ports 136, a larger or smallernumber of ports may be used depending on the implementation. Optionallyone or more LEDs 138 may be provided to indicate when power is connectedto the power distribution unit 24.

In some implementations, the power distribution unit 24 includes acontroller or microprocessor 129 to manage the functions of the powerdistribution unit 24. In some implementations, the base unit has a firstcommunication unit 53 and the power distribution unit 24 has a secondcommunication unit 131. In some implementations, the first communicationunit 53 and the second communication unit 131 use at least one of thethree exposed track power contacts 62 of the foldable track 14 to passcommunication signals between the first communication unit 53 and thesecond communication unit 131. Optionally, the base unit controller 44can verify, via the communication signals, whether the powerdistribution unit 24 is authorized to receive power from the foldablepower track 14. If the power distribution unit 24 is not authorized toreceive power from the foldable power track 14, the base unit controller44 can turn off switch 46 to cease supplying power to the foldable powertrack 14.

In some implementations, a third communication unit (not shown) isdisposed within the magnetic electrical connector 18. In someimplementations, the first communication unit 53 and the thirdcommunication unit use at least one of the three exposed track powercontacts 62 of the foldable track 14 to pass communication signalsbetween the first communication unit 53 and the third communicationunit. Optionally, the base unit controller 44 can verify, via thecommunication signals, whether the magnetic electrical connector 18 isauthorized to receive power from the foldable power track 14. If themagnetic electrical connector 18 is not authorized to receive power fromthe foldable power track 14, the base unit controller 44 can turn offswitch 46 to cease supplying power to the foldable power track 14.

FIG. 33 is a broken apart view showing constituent parts of an examplepower distribution unit 20. As shown in FIG. 33, the outside body of thepower distribution unit 20 may be formed using a clamshell design, witha clamshell top 140 and clamshell bottom 142 that are screwed togetherusing screws. Removable top and bottom front shields 146, 148, areprovided in the area surrounding the ports 110. In some implementations,the front shields are removable without separating clamshell top 140from clamshell bottom 142. In some implementations, shields 146 haveapertures 150 sized to engage and retain specially designed electricalplugs (i.e. specially designed USB plug inserts) to hold the USB plugsin the ports 110 so that the USB plug cannot be removed from the port110. In other embodiments the shields are configured to engage andretain power whips 124 to prevent the power whips from being removedfrom the power distribution unit 120.

FIGS. 34-39 show a new and original design for an example base unitaccording to an implementation. In FIGS. 34-39, FIG. 34 is a frontperspective view of the base unit. FIG. 35 is a front view of the baseunit of FIG. 34. FIG. 36 is a rear view of the base unit of FIG. 34.FIG. 37 is a right side view of the base unit of FIG. 34. The left sideview of the base unit is a mirror image of the right side view. FIG. 38is a top plan view of the base unit of FIG. 34. FIG. 39 is a bottom planview of the base unit of FIG. 34.

FIGS. 40-45 show a new and original design for a magnetic connectoraccording to an implementation. In FIGS. 40-45, FIG. 40 is a topperspective view of the magnetic connector. FIG. 41 is a bottomperspective view of the magnetic connector of FIG. 40. FIG. 42 is afront view of the magnetic connector of FIG. 40. The rear view of thebase unit is a mirror image of the front view. FIG. 43 is a right sideview of the magnetic connector of FIG. 40. The left side view of thebase unit is a mirror image of the right side view. FIG. 44 is a topplan view of the magnetic connector of FIG. 40. FIG. 45 is a bottom planview of the magnetic connector of FIG. 40.

FIGS. 46-52 show a new and original design for power distributionaccording to an implementation. In FIGS. 46-52, FIG. 46 is a topperspective view of a power distribution unit. FIG. 47 is a bottomperspective view of the power distribution unit of FIG. 46. FIG. 48 is afront view of the power distribution unit of FIG. 46. FIG. 49 is a rearview of the power distribution unit of FIG. 46. FIG. 50 is a right sideview of the power distribution unit of FIG. 46. The left side view ofthe power distribution unit is a mirror image of the right side view.FIG. 51 is a top plan view of the power distribution unit of FIG. 46.FIG. 52 is a bottom plan view of the power distribution unit of FIG. 46.

The following reference numerals are used in the drawings:

10 rapidly deployable floor power system

12 base unit

14 foldable power track

16 track power cable

17 track input terminal

18 magnetic connector

20 power distribution system

22 power distribution cable

24 power distribution unit

25 desk

26 power cord

28 rigid track section

30 flexible track connector

32 dual ended magnetic power cable

34 room

36 AC power input

38 GFI/fuse

40 AC power outlet

42 AC-DC transformer

44 controller

46 Switch

48 DC power output

50 power contact

52 magnetic attractor

53 communication unit

54 protection circuit

56 power conditioner

58 load sensor

60 LED

62 track power contact

64 magnetic attractors

66 wire

68 termination end

70 top surface

72 beveled edges

74 channel

76 magnetic attractor grooves

78 power contact grooves

80 power contact channels

82 rigid tail pieces

84 flexible ribbon

86 electrical connectors

88 brass tip

90 wire

92 tongue

94 wedge-shaped retaining clasps

95 strain relief member

96 region

98 legs

100 contact

101 aperture

102 printed circuit board

104 spring

106 base

112 lower surface

114 top interior surface

116 cavity

122 female low voltage DC output port

124 power whip

126 DC connector

128 DC power input

129 controller

130 first DC-DC converter

131 communication unit

132 first set of DC ports

134 second DC-DC converter

136 second set of DC ports

138 LED

140 clamshell top

142 clamshell bottom

146 top shield

148 bottom shield

150 aperture

A number of implementations have been described. Nevertheless, it willbe understood that additional modifications may be made withoutdeparting from the scope of the inventive concepts described herein,and, accordingly, other implementations are within the scope of thefollowing claims.

What is claimed is: 1-29. (canceled)
 30. A method of rapidly deploying afloor power system within a room, the method comprising the steps of:unfolding a foldable power track onto a floor of the room, the foldablepower track including a plurality of straight rigid track sections withexposed DC power contacts on a top surface and a plurality of flexibletrack connectors electrically and mechanically interconnecting thestraight rigid track sections; electrically connecting a base unit tomains power, the base unit containing an AC to DC converter to convertAC power received from the mains power to a low voltage DC power, andoutput the low voltage DC power on a DC power output; and electricallyconnecting the base unit to the foldable power track using a power cordelectrically and mechanically fixed to the foldable power track at oneend and having a magnetic electrical connector on the other end tointerconnect with the DC power output of the base unit.
 31. The methodof claim 30, further comprising the steps of: unfolding at least asecond foldable power track onto the floor; and using a power cordelectrically and mechanically fixed to the second foldable power trackat one end and having a magnetic electrical connector on the other end,to electrically interconnect the second foldable power track with theexposed DC power contacts on the top surface of the first foldable powertrack.
 32. A power distribution unit, comprising: a plurality of femalelow voltage DC output ports; a DC-DC transformer configured to convertDC power received at a DC power input to a first voltage level forpresentation at some or all of the plurality of female low voltage DCoutput ports; a plurality of whips connected to the DC output ports; andan external body formed as a top clamshell, a bottom clamshell, and ashield configured to retain the plurality of whips from being removedfrom the power distribution unit.
 33. The power distribution unit ofclaim 32, wherein each whip has a male plug that engages one of the DCoutput ports on a first end, and the shield holds the male plug in therespective port so that the plug cannot be removed from the port. 34.The power distribution unit of claim 33, wherein each whip has a male DCconnector on a second end to connect to a female port of an electronicdevice.
 35. The power distribution unit of claim 33, wherein the shieldhas apertures sized to engage and retain electrical plug inserts toretain the male plugs in the respective ports.
 36. The powerdistribution unit of claim 33, wherein the DC-DC transformer is furtherconfigured to convert DC power received at a DC power input to a secondvoltage level.
 37. The power distribution unit of claim 36, wherein thepower distribution unit is configured to present the first voltage levelat a first subset of the plurality of female low voltage DC output portsand is configured to present the second voltage level at a second subsetof the plurality of female low voltage DC output ports.